recommendation subject: cement kiln

RECOMMENDATIONSubject: Cement Kiln

Revision No.: 01 Date Issued: 22/02/17 Page: 1 of 19

OSYMEN (CHINA) REFRACTORIES CO., LIMITED 欧西曼（中国）耐火材料有限公司 Add: Block 3, Huake Road3, Binhai Hi-Tech Industry Zone, Tianjin, CHINA. (Post Code: 300000) 地址：中国天津市滨海高新区华科三路一号三幢 (邮政编码：300000) Web网址: www.osymen.com Tel电话: +86-22-58650449 E-mail: [email protected] (海外销售部 Overseas sales department) ； [email protected] (商务服务部 Business services department) 、

企业简介

Company Profile…………………………………………………………………………………………………………………………………………………..…….02

推荐砌筑方案

Lining Recommendation ………………………………………………………………………………………………………………………………………………03

欧西曼根据多年的经验提供如下四套方案供客户参考：

OSYMEN’S recommendations according to year’s experience.…………………………………………………………………..……………………………04

水泥窑砖指标

Technical Specification for Cement Brick……………………………………………………………………………………………………………...…………..05

回转窑用耐火材料的损毁机理/

Mechanism of refractory damage in rotary kiln…………………………………………………………………………………………...……………………….08

回转窑各段带耐材损毁原因和要求/

Reason of damage and demand of refractory for each zone of rotary kiln………………………………………………………..………………………….08

回转窑砌筑/

Installation of rotary kiln……………………………………………………………………………….………………………………………………………….……09

烘窑及挂窑皮/ .

Heating up and coating of kiln……………………………………………………………………………….…………………………………………….……….....10

砖型： VDZ砖型和ISO 砖型对比

Brik shapes: VDZ vs. ISO…………………………………………………………………………………………………………………………………….…………11

纸板（碱性砖）

Cardboards (basic bricks)………………………………………………………………………………………………………………………….…………………..11

大储存周期

Maximum shelf life……………………………………………………………………………………………………………………………………………………….12

镁质砖的水化

Hydration of magnesia bricks…………………………………………………………………….……………………………………………………….…….……..12

湿砖和湿的砖衬

Wet bricks and wet lining sections…………………………………………………………………………………………………………..…………….…….……13

尺寸公差/

Brick Tolerance………………………………………………………………………………………………………….………………………………….…….………14

回转窑用耐火砖尺寸表/

STANDARD ROTARY KILN BRICKS…………………………………………………………………………………………………………………….…….………14

水泥窑耐火材料业绩

Reference for Cement Kiln………………………………………………………………………………………………………………………………………………19




欧西曼是一家致力于向全球客户提供耐火材料和相关服务的专业公司。公司总部位于中国天津市滨海新区海泰高新区，距离天津港仅60公里。欧西曼耐材主要服务于四大工业领域：钢铁工业；水泥回转窑；有色冶炼炉；玻璃窑。 OSYMEN is a specialized Refractories manufacturer and related services for global customers. Headquarter in Binhai Hi‐Tech Industry Park, Tianjin, China. OSYMEN mainly serves 4 industrial areas:

1) Steel Industry 2) Non‐ferrous Metal Furnaces 3) Cement Rotary Kilns 4) Glass Furnaces

碱性砖生产基地

Basic Refractories Production Base:

专注生产碱性耐火材料，占地面积20万m2，有员工600人，工程师80人，其中高级工程师15人，总投资3.5亿元人民币。现有3条超高温隧道窑生产线，年生产烧成制品9万吨，不烧制品4万吨，不定型制品2万吨。

Specialized in the production of magnesia refractories, it covers an area of 200000 square meters, with 600 staff including 80 engineers, 15 staff are senior engineers.

The total investment is 350 million RMB. There are now 3 high temperature tunnel kilns, with 90,000 tons burnt bricks capacity, unburnt bricks 40,000 tons and unshaped products 20,000 tons.

铝-硅系列生产基地

Al-Si Series Refractories Production Base:

专注生产铝硅系列耐火材料，研发中心拥有独立测试，研究和产品创新能力，拥有13名高级工程师，69名工程师和29名助理工程师。使其本身成为供应粘土

砖，高铝砖，红柱石砖，莫来石砖，CDQ炉砖，硅砖，连铸耐火产品等领先的耐火材料制造商之一。 Specialized in the production of Al‐Si series refractories, it has strong research and development capability, R&D center is full responsible for test, research and product

innovation, with 13 Senior Engineers, 69 Engineers and 29 assistant Engineers. Enables itself to be one of the leading refractory manufacturers for supplying Clay bricks,

High Alumina bricks, Andalusite bricks, Mullite bricks, bricks for CDQ Furnace, Silica bricks, Con‐casting refractory products, and so on.

电熔砖生产基地

Fused Cast Refractories Production Base:

专注于电熔耐火材料生产，员工430人，占地面积46700平方米，年生产能力达20000吨。自有知识产权涵盖产品制型、熔化、浇铸、加工、组装等工序。2008

年起聘请日本管理专家全面推行精细化管理…。主要产品有：熔铸锆刚玉AZS33#、AZS36#、AZS41#，各类特殊用途耐火材料，成型砖，锆质、锆铝质捣打料、

浇铸料等，广泛应用于玻璃、石化、冶金、建材等行业。拥有胸墙复合保温砖、蓄热室用筒子砖、旋转管、匀料筒、料棒、坩埚等特色产品。 Specialized in the production of Fused Cast Refractories, 430 employees with 46700 square meters areas, and the annual casting capacity can reach to 20,000 tons.

Started working with Japanese Management Company to carry out TPS management system in the company. At this moment, It has got two automatic production lines.

The material batch feeding process and melting process are under computer digitized management. And has 42 sets cutting and grinding equipments, 8 sets specialized assembling equipments and 3 sets assembling platform of 2050 square meters, which can enable to assembling 1000 tons float glass furnace. In addition, imported some

advanced test and analysis equipments, such as the Rader inner detect equipments can test the shrinkage of blocks, the X‐RAY Fluorescence analyzer can give us the

accurate chemical analysis within 15 minutes.




推荐砌筑方案

Lining Recommendation

OSYMEN

BRAND

Steel Fiber

Corundum

Castable

KM

RMAS- RMFS- RMAS- RASM- RASM- High Alumina

Strengthened

Castable

KM

RMFS- RMNS- RMNS- RASM- RYRS

RMNS- RMCR- RMFS- RYRS RMPA

部位

ZONES

A B C D E F G

前窑口

OUTLET

ZONE

下过渡带

LOWER

TRANSITION

ZONE

烧成带

BURNING

ZONE

上过渡带

UPPER

TRANSITION

ZONE

安全带

SAFTY

ZONE

分解带

CALCINING

ZONE

后窑口

INLET

ZONE

1. 过渡带：由于没有窑皮的保护，那么在过渡带使用的耐火砖必须具有良好的热震稳定性和耐机械磨损性。实践证明镁尖晶石砖是成熟，稳定的砖种。

硅莫砖作为一个新品种，也有很好的表现。

2. 烧成带：耐火砖如果没有窑皮的保护，将会在极短的时间内损坏。所以选用的耐火砖必须首先具备良好的挂窑皮性能，另外还需要优异的热震稳定性，

机械强度，以及抗过热损毁的性能。镁铬砖是好的首选，但考虑到铬污染的问题，镁铁尖晶石和镁锰尖晶石砖是成熟的替代材料。

CEMENT ROTARY KILN REFRACTORIES LINING RECOMMENDATIONS

Transition zone：Without clinker coating protection at transition zones refractory at these zones must have good thermal shock stability and mechanical

abrasion. The practice shows that RMAS bricks are the most mature and stable one. RASM as a new brand also performs well.

Burning zone：Refractory without clinker coating protection would be damaged in short time. Therefore refractory should have good properties of clinker

coating, and very good thermal shock stability, mechanical strength and resistance to overheat damage. RMCR are best choices. However, RMAS and

RMNS bricks can be mature replacement considering the chrome contamination problem.

各品质砖特性比较/Nature comparison of the bricks：

(1) 挂窑皮性能/Clinker coating：RMCR>RMFS>RMNS>RMAS>RASM

(2) 高温机械柔性/Hot mechanical flexibility：RMAS>RMCR>RMNS>RMFS

(3) 耐磨性/Resistance against weariness：RASM>RMFS>RMAS >RMCR

(4) 热传导性/Heat conductivity：RMAS>RMFS>RASM

(5) 耐侵蚀性/Refractoriness：RMCR>RMNS>RMFS>RMAS




欧西曼根据多年的经验提供如下四套方案供客户参考：

OSYMEN’S recommendations according to years experience:

欧西曼水泥窑配置方案

OSYMEN CEMENT

REFRACTORIES DESIGN

适用条件

APPLICATION

烧成带

BURNING ZONE

上过渡带

UPPER

TRANSITION

下过渡带

LOWER

TRANSITION

备注

NOTE

加强配置

Reinforced Design AS

≥6,000 t/d

或燃烧轮胎等废料

RMFS-A RMAS-AS RMAS-AS

RMNS-A RMAS-AS RMAS-AS 无铬化配置

Chrome-free design

标准配置

Standard Design

A 4,000-6,000 t/d

RMNS-A RMAS-B RMAS-A

RMNS-A RMNS-A RMNS-A

RMFS-A RMFS-15A RMFS-15A 无铬化配置

Chrome-free design

B 3,000-4,000 t/d

RMNS-B RMAS-B RMAS-A

RMNS-B RASM-165 RASM-165

RMFS-B RMFS-15B RMFS-15B 无铬化配置

Chrome-free design

C ≤2,500 t/d

RMNS-B RMAS-C RMAS-B

RMFS-B RASM-155 RASM-165 无铬化配置

Chrome-free design




水泥窑砖指标

Technical Specification for Cement Brick:

镁铝尖晶石砖/ Magnesia Aluminum Spinel Bricks

是由镁砂和合成尖晶石为主要原料，高温烧结而成。镁尖晶石砖是在全世界使用为广泛，为成熟的，经济的，能适应任何情况的

水泥窑过渡带用砖。

它具有抗热震稳定性优，抗热负荷性能优，抗化学侵蚀性能优，抗过热性损毁性能优，抗氧化还原性能优，高温机械柔性优，耐磨性能

优等优点。但是挂窑皮性能较差，导热系数大，故我们首选推荐镁铝尖晶石砖作为水泥回转窑过渡带用砖

Made of magnesia and synthetic spinel, processed by high temperature sintering. RMAS Bricks are most extensively, most mature

and most economical bricks used in the world for cement rotary kiln transition zone under any condition.

It has many characteristics such as excellent resistance to thermal shock, thermal load damage, and chemical corrosion, overheat fatigue, oxidation

reduction and wearing as well as high temperature mechanical flexibility. However, it is not good in clinker coating and high in thermal conductivity. So, we

recommend it as the first choice for rotary kiln transition zone bricks.

OSYMEN BRAND

MgO

Al2O3 显气孔率Apparent Porosity

体积密度 Bulk Density

常温耐压强度Cold Crushing

Strength

荷重软化温度 TaRefractoriness

under Load

热震稳定性,次 Thermal Shock

Resistance

热膨胀率 1000℃ Thermal

Expansion

热导率 1000℃

Thermal Conductivity

% % % g/cm3 MPa （Ta）oC

950 oC Air cycles

% W/m.k

RMAS-5AS ≥88.0 5-7 ≤16.0 ≥2.95 ≥75 ≥1700 ≥100 1.20 3.00

RMAS-5A ≥88.0 5-7 ≤17.0 ≥2.95 ≥70 ≥1680 ≥100 1.20 3.00

RMAS-5B ≥87.0 5-7 ≤18.0 ≥2.92 ≥65 ≥1650 ≥80 1.20 3.00

RMAS-10AS ≥84.0 9-11 ≤16.0 ≥2.95 ≥75 ≥1700 ≥100 1.20 2.95

RMAS-10A ≥84.0 9-11 ≤17.0 ≥2.93 ≥70 ≥1680 ≥100 1.20 2.95

RMAS-10B ≥82.0 9-11 ≤18.0 ≥2.92 ≥65 ≥1650 ≥80 1.20 2.95

RMAS-15AS ≥80.0 13-15 ≤16.0 ≥2.95 ≥75 ≥1700 ≥100 1.20 2.80

RMAS-15A ≥80.0 13-15 ≤17.0 ≥2.90 ≥70 ≥1680 ≥100 1.20 2.85

RMAS-15B ≥78.0 13-15 ≤18.0 ≥2.90 ≥65 ≥1650 ≥80 1.20 2.85

镁铁尖晶石砖/ Magnesia Hercynite Spinel Bricks

是由镁砂和铁铝尖晶石为主要原料，高温烧结而成。适用范围广，可在烧成带和过渡带同时使用它，会减少备用库存，降低成本。

具有挂窑皮性能良，抗热震稳定性良，窑皮形成迅速而稳定，不易剥落，筒体温度低。抗化学侵蚀性能优，抗过热性损毁性能优，抗氧

化还原性能好，没有碱裂、疏松现象。抗热负荷疲劳性能良，特别是高温机械柔韧性优，耐磨损性能好，尤其是在回转窑的轮垫处它是

佳选择。

Made of magnesite and hercynite, RMFS processed by high temperature sintering. It was widely used both in burning and transition

zone. It can reduce the standby inventory and thus lower cost. It is good in clinker coating and resistance to thermal shock. Clinker coating can form rapidly

and stably. The coating doesn’t fall easily and thus it reduce the kiln proper temperature. It is excellent in resistance to chemical corrosion, overheat damage,

oxidation reduction without conditions such as alkali cracking or loosening. It is good in resistance to thermal load fatigue, especially in high temperature

mechanical flexibility and wearing resistance. It is the best choice to be used at kiln tire areas.

OSYMEN BRAND

MgO Fe2O3

+Al2O3

显气孔率Apparent Porosity



Strength


under Load


Resistance


Expansion

热导率 1000℃ Thermal

Conductivity


950 oC Air cycles

% W/m.k

RMFS-15A 86.0 7-12 ≤15.0 ≥2.95 ≥70 ≥1700 ≥100 1.15 2.60

RMFS-15B 84.0 7-12 ≤16.0 ≥2.92 ≥65 ≥1680 ≥90 1.15 2.60




镁锰尖晶石砖/ Magnesia Galaxite spinel brick

以镁砂为主要原料，添加含锰尖晶石及锰氧化物，中高温烧制而成。是回转窑无铬化的主打产品。RMNS-15A 可在烧成带和过渡带同时

使用，能减少备用库存品种，降低成本。

在水泥回转窑使用挂窑皮性能优良，热震稳定性高。抗化学侵蚀性能优。抗过热损毁性能优。高温机械柔性和耐磨性优。抗热负荷疲劳

性能良，特别适用于温度频繁变化的环境。

RMNS is made primarily of magnesite under medium to high temperature burning with addition of some alumina, manganese oxide. It can be used

both in burning and transition zones in rotary kiln instead of magnesia chrome brick.

It works well in cement rotary kiln in terms of clinker coating, with high in thermal shock resistance. It is excellent in resistance to chemical corrosion, overheat damage

and wearing as well as high temperature mechanical flexibility. It is good in resistance to thermal load fatigue, especially suitable for frequent temperature change.

OSYMEN BRAND

MgO MnO2

+Al2O3

显气孔率Apparent Porosity



Strength


under Load


Resistance


Expansion

热导率 1000℃ Thermal

Conductivity


950 oC Air cycles

% W/m.k

RMNS-10A ≥88.0 6.0-9.0 ≤16.0 ≥2.94 ≥80 ≥1700 ≥100 1.20 2.90

RMNS-10B ≥88.0 6.0-9.0 ≤17.0 ≥2.92 ≥70 ≥1650 ≥100 1.20 2.90

RMNS-15A ≥84.0 12.0-15.0 ≤16.0 ≥2.94 ≥80 ≥1700 ≥100 1.20 2.90

镁铬砖/ Magnesia Chromite Bricks

是由镁砂和铬铁矿为主要原料，添加了铁为主的复合材料为原料，高温烧结而成。镁铬砖曾是全世界使用为广泛，为成熟的，能

适应任何情况的，也经济的水泥窑烧成带用砖,在过渡带也可以使用它。它具有挂窑皮性能优，抗热震稳定性良，抗热负荷疲劳性能

良，抗化学侵蚀性能优，抗过热性损毁性能优，抗氧化还原性能良。缺点是有人指责它破坏环境。为此欧西曼发展了低铬镁铬砖，以及

完全不含铬的产品，等多种替代传统镁铬砖的产品。

请注意：欧西曼的所有含铬产品都经过专有的无害化技术处理，尽量降低对环境的潜在危害。现有产品全部符合美国的严格环保标准，

客户可放心使用。

Made of dead burned magnesia and chromites, processed by high temperature sintering. RMCR are most extensively used in the world. They are

used at burning zone and transition zone of cement kilns. They are adaptive to any conditions and economical. With properties of good clinker coating，sound thermal

shock resistance, good heat load weariness resistance，good chemical corrosion resistance，good thermal fatigue resistance, good oxidation-reduction resistance.

Disadvantages are hazardous to environment. OSYMEN therefore developed low chrome magnesia chrome bricks or chrome free products as alternatives to traditional

RMCR products.

Please note：All OSYMEN chrome containing products has been treated with hazard free technologies, and try our best to reduce the potential harm to the environment.

All our present product meet the standard of US environment protection. Customer can use at ease.

OSYMEN BRAND

MgO

Cr2O3 显气孔率Apparent Porosity



Strength


under Load


Resistance

热膨胀率 1000 oC Thermal

Expansion

热导率 1000 oC Thermal

Conductivity


950℃ Air cycles

% W/m.k

RMCR-A ≥78.0 2-4 ≤16.0 ≥2.95 ≥70 ≥1700 ≥100 1.05 2.10

RMCR-B ≥76.0 2-4 ≤17.0 ≥2.92 ≥65 ≥1680 ≥100 1.05 2.10




硅莫砖/Alumina-Sic-Mullite Bricks

是以刚玉、矾土和碳化硅为主要原料，中温烧结而成。硅莫砖是近几年在中国迅速推广的在过渡带使用的新产品，在大多数时候

它的使用效果都比镁尖晶石砖好。它抗热震稳定性和热负荷疲劳性能特优，高温机械柔性特优，耐磨性能特优，抗还原性气氛性能

特优。其导热系数低，降低了窑的筒体温度，防止回转窑筒体和托轮受热膨胀，隔热效果优，节能效果好。体积密度小，有效降低

了窑筒体、托轮和动力系统负荷。

Made of Alumina Corundum and Silicon Carbide，processed by medium temperature sintering. RASM Bricks are recently promoted

rapidly in China as new products at transition zone.

It is excellent in resistance to thermal shock, thermal load fatigue, high temperature mechanical flexibility, and wearing as well as oxidation

reduction. With its low thermal conductivity factor, it can reduce the drum temperature and prevent the kiln drum and tire from expansion and good in insulation and save

energy. Because it is low in bulk density, it effectively reduce the load on drum, tire and power system.

OSYMEN BRAND

Al2O3 SiO2

+SiC 体积密度

Bulk Density

常温耐压强度 Cold Crushing

Strength

荷重软化温度 Ta Refractoriness under

Load

热震稳定性,次Thermal Shock

Resistance

耐磨系数 Wear-resisting

Coefficient

热导率 1000 oC Thermal

Conductivity

% % g/cm3 MPa (Ta) oC 950 oC Air cycles cm3 W/m.k

RASM-168S ≥65.0 27-31 ≥2.75 ≥100 ≥1680 ≥100 6.0 1.25

RASM-168 ≥65.0 27-31 ≥2.70 ≥100 ≥1650 ≥100 7.0 1.25

RASM-165S ≥60.0 24-28 ≥2.70 ≥100 ≥1630 ≥100 7.0 1.30

RASM-165 ≥60.0 24-28 ≥2.65 ≥100 ≥1600 ≥100 8.0 1.30

RASM-155 ≥57 21-25 ≥2.60 ≥95 ≥1500 ≥90 9.0 1.35




回转窑用耐火材料的损毁机理/

Mechanism of refractory damage in rotary kiln

1. 化学侵蚀：碱的硫酸盐和氯化物等组分挥发凝聚反复循环：水泥熟料中的 C2S、C3A、C4AF 等的渗入等作用加剧结构剥落。

2. 热应力损毁：由于窑内气体温度比物料温度高很多，窑每转一圈，窑衬表面温度变化幅度为 150-250oC, 窑衬耐火材料受到周期性的热冲击。

3. 机械应力损毁：窑衬由于受窑的旋转而产生的砖砌体交替变化的径向和轴向机械应力，以及煅烧物料的冲刷磨损。

4. 高温损毁：通常情况不是主要因素，局部温度过高也会造成窑衬的快速损毁。

1. Chemical corrosion: component such as alkali sulfate and chloride volatile, condense, again and again; penetration of ingredient such as C2S, C3A and

C4AF in the cement clinker cause structural peel off.

2. Thermal stress: As the gas temperature is higher than that of material in the kiln, the lining surface temperature change will be 150-250oC when the kiln

rotates. The refractory will suffer from cycle impact.

3. Mechanical stress: radial and axial mechanical stress is generated on the lining when the kiln rotate due to the brick construction. The lining is also

rubbed by the calcinated material.

4. High temperature: though it is generally not a major factor of damage. Regional overheat will lead to rapid damage of the kiln lining.

化学侵蚀损毁，约占损毁的 27%

About 27% due to chemical corrosion 机械应力损毁，约占损毁的 37

about 37% due to mechanical

stress

热应力损毁，约占损毁的 36%

about 36% due to thermal stress

回转窑各段带耐材损毁原因和要求/

Reason of damage and demand of refractory for each zone of rotary kiln 段带 Zone

损毁原因 Reason of damage

对耐材的要求 Demand on refractory

分解带 Calcining zone

原料磨损；热剥落和结构剥落；耐火砖脱落。

Raw material abrasion; Thermal and structure peel off; Refractory brick fall off.

耐磨性耐热剥落和结构剥落性；低热膨胀性。

Abrasion resistance; Resistance to thermal and structure peel off; Low thermal expansion

过渡带 Transition zone

热剥落；热面损蚀；结构剥落。

Thermal peel off; Hot face corrosion; Structural peel off.

抗热剥落；低气孔率和低透气性；耐结构剥落性。

Resistance to thermal peel off; Low apparent porosity and permeability; Resistance to structural peel off.

烧成带 Burning zone

与熟料化学反应；外来成分渗入，产生结构剥落；高温引起的侵蚀。

Reaction with clinker; Structure peel off due to foreign material penetration; Corrosion due to high temperature.

抗侵蚀性；抗结构剥落性；挂窑皮附着性。

Corrosion resistance; Resistance to structural peel off; Resistance to clinker coating adhesiveness.

冷却带 Cooling zone

熟料磨损；温度变化引起的热剥落；出料口周围的机械剥落。

Abrasion by clinker; Thermal peel off due to temperature change; Mechanical peel off around outler.

耐磨性；耐热剥落性；应力释放能力

Abrasion resistance; Resistance to thermal peel off; Stress release capability.




回转窑砌筑/

Installation of rotary kiln

1. 砌筑：焊缝要焊实打磨，筒体要清洁干燥，基准线要划在中心线上，砖衬要对准窑轴，环砌，砖圈不能砌的相互咬合，要与窑内垂直焊缝精确平行。松

紧要适度，轴向不能留膨胀缝。锁缝砖不得直接连用。碱性砖的径向需留膨胀缝，要留的均匀（每圈须留 2mm，碱性砖都带纸板即可），轴向不需要额

外的膨胀缝。硅莫砖，高铝砖，轻质砖不需要膨胀缝。火泥湿砌时，抹泥要均匀，厚度应控制在<1.5mm。使用钢板砌筑时钢板的分布要均匀（尤其不能

再一条缝中插入两块钢板），砖的大头必须紧靠窑体，以免其后发生松弛或扭曲。水平缝总是严格指向窑轴方向。对任何不规则焊缝和窑扭曲部分都须

用火泥补偿，使此处扔能与其余砖圈平行。新旧砖衬必须结合紧凑，因旧砖衬的结合面是不均匀的，必须用加工砖。加工砖的长度不少于 80mm,以保证

新旧砖衬之间坚实稳定的结合。

2. 注意事项：

a> 挡砖圈与砖衬之间只能用一块钢板。

b> 轮带区内不能改变砖。

c> 烧成带不能采用不同品质的碱性砖。

d> 砌筑时用木锤或橡皮锤，严禁使用铁锤。

3. 砌筑常见问题：a)错位；b)倾斜；c)灰缝不均匀；d)爬坡；e)离中：即在弧形砌体中砖环与壳体不同心；f)重缝：即上下层灰缝相叠合，两层间只允许有

一条灰缝；g)通缝：即内外水平层灰缝相合，甚至露出金属壳是不允许的；h)张口：即在弧形砌体中灰缝内小外大；i)脱空：即灰浆在层间，砖间及壳体

间不饱满；j)毛缝：即砖缝未勾抹，墙面不清洁；k)蛇形弯：即纵缝，环缝或水平缝不呈直线而呈波浪形弯曲；l)砌体鼓包，抽签；m)混浆：错用了泥浆。

1. Installation: kiln shell welding joints should be fully welded and polished, kiln inside surface should be cleaned and dried. Measure and mark the kiln

axis. Align the kiln bricks along the kiln axis. Proceed on either directions. Install the bricks up to the kiln center. Continue installation to form brick rings

that are perpendicular to the welding joint. Make sure the brick ring gaps are closed. Close bricks should not be used contunually one after another.

Basic bricks expansion ring gap should be evenly retained (2mm ring, basic bricks attached with card boards can alright), axial enpansion gas is not

necessary. Alumisic bricks, high alumina bricks and light bricks do not need expansion gap. Mortar should be spread evenly, limited thickness <1.5mm.

when steel plates are used during installation, they should be evenly distributed (do not put 2 plates in the same gap). Big side of the brick should be

closed attached to the surface of the kiln, to prevent loosening or deforming. Horizontal gap must be strictly directed to the axis of the kiln. Any irregular

welding joints and deformed part of the kiln must be closed by mortar so as to keep other brick brick rings parallel. New bricks and old bricks must be

tightly attached. Because of the eneven surfaces of old bricks, trimming bricks is necessary, trimming old bricks length should be more than 80mm to

ensure tight attachment of old and new bricks.

2. Notes:

a> Only 1 steel plate can be inserted between lining and stopping ring.

b> Do not trim or remodel bricks at kiln tire area.

c> Do not use different typs of basic bricks at burning zone.

d> Do not use steel hammer during installation, use wooden hammer or rubber hammer.

3. Installation problems: a) dislocation. b) inclination. c) uneven mortar gaps. d) sloping. e) decentralization. f) double gaps. g) penetration gaps. h) open

mouth. I) unful mortal gaps. j) unclean seam. k) snake curve. l) swelling bump. m) mistake mortar.




烘窑及挂窑皮/

Heating up and coating of kiln

烘窑是水泥生产过程中必不可少的一个环节。烘窑共分为三个阶段：

1）排潮排水阶段，窑尾温度为常温-200oC。

2）砖衬线性膨胀阶段，窑尾温度为 200-950 oC。

3）产生液相阶段，窑尾温度 950-1100 oC。

烘窑阶段，回转窑要转动。窑的转速应根据窑衬温度而缓慢提高，具体为：300-600 oC 每 30 分钟转 1/3 圈，600-900 oC 时每 15 分钟转 1/3 圈，900-1200oC

时需要持续而缓慢的窑转，即约每分钟转 0.8 圈。烘到窑尾温度摄氏 950oC（窑内烧成带约 1450 oC），即可开始投料挂窑皮。挂窑皮时投料量时正常生产时

的 70%，窑的转速为每分钟转 2.4-2.6 圈。温度要保持稳定，三个班后（24 小时）窑皮已基本挂满稳定，即可正常生产投料，转速达每分钟 3.2-3.5 圈/分。

Heating up of the kiln is indispensable procedure during cement production. It can be divided as three stages:

1) moisture removal and draining, the kiln end temperature is at between to 200 oC.

2) linear expansion of brick lining, the kiln end temperature is between 200-950 oC.

3) liquid pahse generation, the kiln end temperature is between 950-1100 oC.

During heating up, the kiln will be rotated. The rotation speed is increased slowly based on the lining temperature. Practically, between 300-600 oC, 1/3 cycle

is rotated per every 30 min.

between 600-900 oC, 1/3 cycle is rotated per every 15 min.

between 900-1200 oC the kiln should be rotated continuously and slowly, at about 0.8 cycle per min.

when kiln end temperature is at 950 oC (the temperature at burning zong will be 1450 oC), feeding for coating can be started. The feeding quantity is about 70%

of that for normal production. The rotation speed is at 2.4-2.6 cycles per min. the temperature should be kept stable. After three shifts (24hours), the coating

is basically full and stable. Normal feeding can started at 3.2-3.5cycles per min.




Brik shapes: VDZ vs. ISO

砖型： VDZ砖型和ISO 砖型对比

General recommendation: Use VDZ shapes for basic lining and ISO shapes for alumina bricks

普遍性的建议：碱性砖适用 VDZ 砖型砌筑，高铝砖适用 ISO 砖型。

Note: for very large diameter kiln (Φ>5.6m) ISO shapes are recommended also for basic bricks, due to the greater taper, which increases lining

stability during kiln start-up.

注意：对于直径很大的窑（Φ>5.6m），建议碱性砖也是用 ISO 砖型，因为 ISO 砖型的锥角更大，在开窑期间可以增加砖衬稳定性。

VDZ linings have approx. 30% more brick joints which provides increased flexibility and thermal shock resistance to the rings.

使用 VDZ 砖型衬砌，砖缝月多了 30%，这样砖环的柔性和抗热震性能更好。

Alumina bricks are usually layed with mortar to adjust greater dimensional tolerance of alumina brick.

高铝砖通常要用火泥湿砌来调整其过大的尺寸公差。

Cardboards (basic bricks) 纸板（碱性砖） Basic bricks have cardboard attached to compensate for higher thermal expansion.

碱性砖贴有纸板，用于补偿过高的热膨胀。

Attached on axial joint (thickness 1.5mm). Burn-out of cardboard is faster than thermal expansion of bricks, so great care must be taken when turning the kiln

during heat-up.

纸板贴在火砖的环向端面（厚度为 1.5mm）。纸板会早于火砖热膨胀烧掉，所以在升温过程中转窑要格外小心。

Metal sheets (magnesia chromite bricks)

预贴钢板（仅限于镁铬砖）

Attached on radial joint of each brick (thickness 0.7mm). start to soften at approx. 600oC and to oxidise at >1000oC thus forming a ceramic bond between

bricks. Must not be confounded with key shims which are driven in to tighten the rings.

钢板贴在每块火砖的大面（厚度 0.7mm）。在 600oC 时预贴的钢板会软化，在>1000oC 时会氧化，在火砖之间形成陶瓷结合。锁砖钢板处不要有预贴钢板，

即剥掉预贴钢板再打入锁砖钢板。




Maximum shelf life

大储存周期

Fireclay and alumina bricks are not susceptible to hydration and can be stored indefinitely.

粘土砖和高铝砖不会水化，储存期是无限的

Mortar should not be stored at customer’s warehouse for more than 12 months.

火泥在仓库中储存不应超过 12 个月

Magnesia bricks are susceptible to hydrate, especially under tropical conditions and when made from high purity, synthetic magnesia. Normally, if the pallets

not to be opened, the bricks can be kept in warehouse one year, no problem for using.

镁质砖易于水化，特别是在热带条件下，或采用高纯度合成镁砂制成的火砖。一般地，如果托盘包装不打开，火砖在仓库中保存一年，不会对使用造成影响。

Hydration of magnesia bricks

镁质砖的水化

Radial cracks (arrows) are an inequivocal sign of hydration; Hydrated bricks cannot be used anymore.

Bricks with radial cracks have lost their mechanical strength and must be discarded.

When knocked with a steel hammer, hydrated bricks sound dull and break easily.

放射状的裂纹（箭头所指）是水化的可能迹象，水化的火砖决不能使用

带有放射状裂纹的火砖已经失去了其机械强度，必须废弃。

铁锤敲击水化火砖，声音闷且易碎。




Wet bricks and wet lining sections

湿砖和湿的砖衬

Magnesia bricks which have become wet must be stacked openly and ventilated at ambient air temperatures until dried cmpletely. Do not use hot air, do not

expose wet bricks to the heat radiated from the kiln shell. After drying, check bricks carefully for radial cracks.

如果镁质砖变湿，必须使其暴露于空气中堆放，并在环境气温中通风干燥直至干透。

New lining sections which have become wet must be removed and replaced by dry bricks.

如果新砌的砖衬变湿，必须拆下换上干燥的砖。

Wet bricks must be removed! 湿砖必须换掉！




尺寸公差/

Brick Tolerance:

l, h = +/- 1 mm

a, b = +/- 0.5 mm

扭曲/ Warpage= -0.5 mm

回转窑用耐火砖尺寸表/

STANDARD ROTARY KILN BRICKS

1. VDZ 砖型系列：（国际通用系列，等中间尺寸恒定为 71.5mm）

The size (a+b)/2 is fixed as 71.5mm. which is the international standard

Item Measurements (mm) Diameter (mm) Volume

a b h l D1 (dm3)

B218 78 65 180 198 2160 2.55

B318 76.5 66.5 180 198 2754 2.55

B418 75 68 180 198 3857 2.55

B618 74 69 180 198 5328 2.55

B220 78 65 200 198 2400 2.83

B320 76.5 66.5 200 198 3060 2.83

B420 75 68 200 198 4286 2.83

B620 74 69 200 198 5920 2.83

B820 73 69.5 200 198 7350 3.11

B222 78 65 220 198 2640 3.11

B322 76.5 66.5 220 198 3366 3.11

B422 75 68 220 198 4714 3.11

B622 74 69 220 198 6512 3.11

B822 73.5 69.5 220 198 8085 3.11

B425 76.5 66.5 250 198 3825 3.54

B625 74.5 68.5 250 198 6208 3.54

B825 73 68.5 250 198 9188 3.54




2. ISO 砖型系列：（国际通用系列，等大端尺寸恒定为 103mm）

The size a is fixed as 103mm. which is the international standard

Item Measurements (mm) Diameter (mm) Volume

a b h l D1 (dm3)

218 103 84 180 198 1952 3.33

318 103 90.5 180 198 2966 3.45

418 103 93.5 180 198 3903 3.50

618 103 97 180 198 6180 3.56

220 103 82 200 198 1962 3.66

320 103 89 200 198 2943 3.80

420 103 92.5 200 198 3924 3.87

620 103 96.2 200 198 6059 3.94

820 103 97.8 200 198 7923 3.98

222 103 80 220 198 1996 3.99

322 103 88 220 198 3021 4.16

422 103 91.5 220 198 3941 4.24

622 103 95.5 220 198 6043 4.32

822 103 97.3 220 198 7951 4.36

425 103 90 250 198 3962 4.78

625 103 94.5 250 198 6059 4.89

825 103 96.5 250 198 8000 4.94




标准缝砖尺寸/ STANDARD KEY/ CLOSURE BRICKS

1. 碱性缝砖尺寸/ BRICKS Key Bricks

Item Measurements (mm) Volume

a b h l (dm3)

P164 58 51 160 198 1.73

P165 65 58 160 198 1.95

P184 58 53 180 198 1.98

P185 65 60 180 198 2.23

P204 58 53 200 198 2.20

P205 65 60 200 198 2.48

P224 58 53 220 198 2.42

P225 65 60 220 198 2.72

P254 58 53 250 198 2.75

P255 65 60 250 198 3.09

P18 83 77 180 198 2.85

P+18 93 87 180 198 3.21

P20 83 76.2 200 198 3.15

P+20 93 86.2 200 198 3.55

P22 83 75.5 220 198 3.45

P+22 63 85.5 220 198 3.89

P25 83 74.5 250 198 3.90

P+25 93 84.5 250 198 4.39

BP18 64 59 180 198 2.19

BP+18 83 77 180 198 2.85

BP20 64 59 200 198 2.44

BP+20 83 76.2 200 198 3.15

BP22 64 59 220 198 2.68

BP+22 83 75.5 220 198 3.45

BP25 64 59 250 198 3.04

BP+25 83 74.5 250 198 3.90




2. 非碱性缝砖尺寸/ Non Basic Key Bricks

Item Measurements (mm) Volume

a b h l (dm3)

P161 71 63 160 198 2.12

P162 78 70 160 198 2.34

P181 71 65 180 198 2.42

P182 78 71 180 198 2.66

P201 71 65 200 198 2.69

P202 78 71 200 198 2.95

P221 71 65 220 198 2.96

P222 78 71 220 198 3.25

P251 71 65 250 198 3.37

P252 78 71 250 198 3.69

P301 71 62 300 198 3.95

P302 78 70 300 198 4.40

3. 磷酸盐砖型系列/ Phophate Brick Series

Item 适用窑内径（m）

Kiln Φ

Measurements (mm) a-b (mm)

Volume

a b h l (dm3)

P11 1.1-1.5 71 60 100 198 11 1.30

P16 1.6-1.9 80 69 120 198 11 1.77

P20 2.0-2.4 81 70 150 198 11 2.24

P25 2.5-2.9 90 80 150 198 10 2.52

P30 3.0-3.2 92 81 180 198 11 3.08

P33 3.3-3.5 83 74 180 198 9 2.80

P36 3.6-3.9 100 90 180 198 10 3.39

P40 4.0-4.2 90 81 200 198 9 3.39

P43 4.3-4.5 97 88 200 198 9 3.66

P46 4.6-4.9 92 84 200 198 8 3.49

PC1-1 1.1-1.5 90 79 100 198 11 1.67

PC1-2 1.1-1.5 60 49 100 198 11 1.08

PC1-3 1.1-1.5 50 39 100 198 11 0.88

PC1-4 1.6-1.9 90 79 120 198 11 2.01

PC1-5 1.6-1.9 60 49 120 198 11 1.29

PC1-6 1.6-1.9 50 39 120 198 11 1.06




PC2-1 2.0-2.9 100 90 150 198 10 2.82

PC2-2 2.0-2.9 70 60 150 198 10 1.93

PC2-3 2.0-2.9 60 50 150 198 10 1.63

PC3-1 3.0-3.9 110 101 180 198 9 3.76

PC3-2 3.0-3.9 70 61 180 198 9 2.33

PC3-3 3.0-3.9 60 51 180 198 9 1.98

PC4-1 4.0-4.9 100 91 200 198 9 3.78

PC4-2 4.0-4.9 70 61 200 198 9 2.59

PC4-3 4.0-4.9 60 51 200 198 9 2.20




水泥窑耐火材料业绩

Reference for Cement Kiln

水泥行业典型客户

CEMENT PLANT CUSTOMER ROTARY KILN OSYMEN BRAND APPLICATION

1 Huaxin （Wuxue） Cement Co., Ltd 6000t/d

￠5.0×70m

RMAS-10A 过渡带

Transition Zone

RMCR-A 烧成带

Burning zone

2 Conch (Fusui) Cement Co., Ltd 5000t/d

￠4.8×74m RMCR-A

烧成带 Burning zone e

3 Jidong Fengruen Cement Co.,Lid 5000t/d

￠4.7×74m RMCR-A


4 Shandong Donghua Cement Co., Ltd 5000t/d

￠4.74×70m

RMCR-A 烧成带

Burning zone

RMAS-10A 过渡带

Transition Zone

5 Pingyin Shandong Cement Co., Ltd 5000t/d

￠4.8×60m RMCR-A


6 Zibo Shandong Cement Co., Ltd 5000t/d

￠4.8×60m

RMCR-A 烧成带

Burning zone

RMAS-10A 过渡带

Transition Zone

7 China Gezhouba Corporation Cement Co.,Ltd 5000t/d

￠4.4×74m

RMFS-15A 烧成带

Burning zone

RASM-168 过渡带

Transition Zone

8 Hubei Shiji Xinfeng Leishan Cement Co., Ltd 5500t/d

￠5.2×63m

RMCR-A 烧成带

Burning zone

RMFS-15A 过渡带

Transition Zone

9 Changzhou Panshi Cement Co., Ltd 5000t/d

￠4.8×60m

RMCR-A 烧成带

Burning zone

RMAS-10A 过渡带

Transition Zone

10 Henan Tongli Cement Co., Ltd 5000t/d

￠4.8×74m

RMCR-A 烧成带

Burning zone

RMAS-10A 过渡带

Transition Zone

11 Henan Dadi Cement Co., Ltd 5000t/d

￠4.8×72m

RMCR-A 烧成带

Burning zone

RMAS-10A 过渡带

Transition Zone

RASM-165 过渡带 Transition Zone RASM-168

12 kiln K5# of Huaxin (Huangshi) Cement Co., Ltd 5000t/d

￠4.74×70m

RMCR-A 烧成带

Burning zone

RMAS-10A 过渡带

Transition Zone

recommendation subject: cement kiln

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